Flat aerosol-generating consumable articles with corrugated layers

Abstract

A substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the consumable article comprising a plurality of stacked layers, the plurality of stacked layers comprising at least a first, substantially flat layer and a second, corrugated layer, the first and second layers being joined to each other, and wherein at least one of the stacked layers is made of or is provided with a sensorial medium that releases an aerosol when heated.

Description

[0001] FLAT AEROSOL-GENERATING CONSUMABLE ARTICLES WITH CORRUGATED LAYERS

[0002] The present disclosure relates to aerosol-generating consumable articles having a substantially flat, planar form factor, configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol.

[0003] Aerosol-generating systems, for example electronic smoking systems, may comprise an aerosol-generating device configured to receive aerosol-generating consumable articles. The aerosol-generating device includes a power supply and electronic circuitry to heat a consumable article that has been inserted into the aerosol-generating device. Heating may be direct heating, for example electrical resistance heating, or may be inductive heating, where eddy currents are induced in a metallic susceptor of the aerosol-generating consumable article by electromagnetic induction, and the eddy currents cause heating in the aerosol-generating article by way of the Joule effect.

[0004] Aerosol-generating consumable articles for use in such aerosol-generating systems comprise an aerosol-generating substrate comprising or consisting of a material that generates an aerosol when heated. The aerosol-generating substrate may be tobacco- based, for example being made of tobacco cast leaf or reconstituted tobacco. Alternatively, the aerosol-generating substrate may be made of a non-tobacco matrix, for example cellulose, provided with pharmaceutical-grade nicotine or other pharmacologically-active agents.

[0005] Many known aerosol-generating systems use aerosol-generating consumable articles having a cylindrical or rod-shaped form-factor.

[0006] The present invention is directed to aerosol-generating consumable articles having a substantially flat, planar form factor, comprising a plurality of stacked layers, and a method of manufacturing such consumable articles.

[0007] According to a first aspect of the present invention, there is provided a substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the consumable article comprising a plurality of stacked layers, the plurality of stacked layers comprising at least a first, substantially flat layer and a second, corrugated layer, the first and second layers being joined to each other, and wherein at least one of the stacked layers is made of or is provided with a sensorial medium that releases an aerosol when heated.

[0008] The consumable article may further comprise a third, substantially flat layer, wherein the second, corrugated layer is sandwiched between the first and third layers.

[0009] Consumable articles with this form-factor and construction may have a number of advantages. Firstly, the corrugations of the second layer may define a plurality of air channels from one edge of the consumable article to an opposed edge of the consumable article, the air channels helping to entrain a flow of aerosol when a user sucks air through the consumable article while the consumable article is being heated in an aerosol-generating device. Secondly, the corrugations of the second layer may help to provide rigidity or crush-resistance to the consumable article without adding excessive weight. Thirdly, the corrugations of the second layer may provide a useful reservoir for sensorial media in liquid or gel form. Fourthly, opposed surfaces of the substantially planar aerosol-generating consumable article may individually or together provide a relatively large surface area for one or more metallic susceptors. A metallic susceptor may be formed as a metal layer or foil on one or other or both of the opposed surfaces, and may have a larger surface area than is possible with metallic susceptors in cylindrical or rodshaped aerosol-generating consumable articles. This may allow the metallic susceptor to be more efficiently heated by electromagnetic induction.

[0010] At least one of the stacked layers may be made of a material that inherently releases an aerosol when heated. The material may comprise tobacco cast leaf, reconstituted tobacco, tobacco leaf, homogenized tobacco or other forms of tobacco, optionally blended with paper or cellulose fibres. The material may comprise a blend of paper or cellulose fibres and a nicotine-containing composition other than tobacco. Such materials may be considered to be made of a sensorial medium that releases an aerosol when heated.

[0011] At least one of the stacked layers may be impregnated with the sensorial medium.

[0012] At least one of the stacked layers may be coated with the sensorial medium.

[0013] In embodiments where at least one of the stacked layers is impregnated or coated with the sensorial medium, the respective stacked layer may be made of a material that does not inherently release an aerosol when heated. Rather, it is the applied sensorial medium that will release an aerosol when heated. However, in some embodiments, a stacked layer made of a material that inherently releases an aerosol when heated may be impregnated or coated with an additional sensorial medium that also releases an aerosol when heated.

[0014] In embodiments where at least one of the stacked layers is impregnated or coated with the sensorial medium, the sensorial medium may be a liquid, or a gel, or a slurry.

[0015] The sensorial medium may comprise nicotine. The nicotine may be pharmaceutical-grade or synthetic nicotine.

[0016] The sensorial medium may comprise tobacco or tobacco extracts. The tobacco or tobacco extracts may be obtained from natural tobacco.

[0017] In some embodiments, the sensorial medium does not comprise tobacco or tobacco extracts.

[0018] Each layer of the aerosol-generating consumable article may be made of or may be provided with the sensorial medium. Each layer may be made of or may be provided with the same sensorial medium. Alternatively, different layers may be made of or may be provided with different sensorial media. Alternatively, not all of the layers are made of or are provided with the sensorial medium. For example, in some embodiments only the first, substantially flat layer is made of or is provided with the sensorial medium. Alternatively, only the second, corrugated layer is made of or is provided with the sensorial medium. Alternatively, only the third, substantially flat layer is made of or is provided with the sensorial medium. In embodiments comprising three layers, two of the layers may be made of or provided with the sensorial medium, and one of the layers may not be made of or provided with the sensorial medium.

[0019] The consumable article may comprise a metallic susceptor. The susceptor, in the form of a metallic element, serves as a heating member for imparting or distributing heat to the consumable article. In particular, the susceptor serves to impart or distribute heat so as to cause the sensorial medium to release an aerosol. The susceptor may be heated directly, for example through application of heat from a resistive electrical heater of the aerosol-generating device, or by passing electrical current through the susceptor from a power source of the aerosol-generating device. The susceptor may be heated by induction, for example through the generation of eddy currents in the susceptor by application of an alternative electromagnetic field from an induction coil of the aerosol-generating device.

[0020] In some embodiments, the first, substantially flat layer is or comprises the metallic susceptor.

[0021] In some embodiments, the third, substantially flat layer is or comprises the metallic susceptor.

[0022] The metallic susceptor may comprise a metal layer formed on the respective substantially flat layer. The metal layer may be formed on a surface of the respective substantially flat layer opposite to a surface joined to the second, corrugated layer.

[0023] Because the substantially flat layer or layers of the consumable article having a substantially planar form-factor has a relatively large planar surface area, it is possible for the susceptor also to have a relatively large surface area, at least compared with thin, elongate, strip-like susceptors that are often used in cylindrical, rod-shaped aerosol-generating consumable articles. Accordingly, embodiments of the present invention may enable more efficient heating or distribution of heat to the sensorial medium than is possible in cylindrical, rod-shaped aerosolgenerating consumable articles.

[0024] The metallic susceptor may comprise or consist of aluminium, aluminium alloy, 8011 aluminium alloy, stainless steel, 304 stainless steel, stainless steel with a nickel coating, or 304 stainless steel with a nickel coating.

[0025] The metallic susceptor may be applied as a thin foil to the respective substantially flat layer, optionally using an adhesive. The metallic susceptor may be applied to the respective substantially flat layer by a deposition process.

[0026] The metallic susceptor may have a thickness of 10 micrometres to 30 micrometres. The metallic susceptor may extend across substantially a whole width of the respective substantially flat layer. The metallic susceptor may extend across substantially a whole width of the respective substantially flat layer. The metallic susceptor may extend across only a part of a width of the respective substantially flat layer. The metallic susceptor may extend across only a part of a length of the respective substantially flat layer. The size, shape and / or material of the metallic susceptor may be selected so as to enable a desired heating profile with an appropriate aerosol-generating device.

[0027] The second, corrugated layer may define a plurality of substantially parallel airflow channels configured to allow a flow of air from one edge of the consumable article to an opposed edge of the consumable article in a plane of the consumable article when the consumable article is inserted into the aerosol-generating device. The parallel airflow channels may provide a greater interface area between a flow of air and the sensorial medium than may be available in cylindrical, rod-shaped aerosol-generating consumable articles. This may allow for more efficient aerosol generation and entrainment of aerosol in the flow of air. The parallel airflow channels may present a lower resistance to draw than is possible in cylindrical, rod-shaped aerosol-generating consumable articles.

[0028] The airflow channels may be configured to provide a resistance to draw from the one edge to the opposed edge of the consumable articles of 0 to 80 millimetres Water Gauge, preferably 0 to 20 millimetres Water Gauge, more preferably 0 to 10 millimetres Water Gauge.

[0029] The sensorial medium may be disposed in corrugations of the second, corrugated layer. The sensorial medium may be disposed only in corrugations on one surface of the second, corrugated layer. Alternatively, the sensorial medium may be disposed in corrugations on both opposed surfaces of the second, corrugated layer. The corrugations may act as reservoirs for the sensorial medium.

[0030] The sensorial medium may comprise at least one of: humectant, flavorant, botanical component, pharmacologically-active agent, gelling agent.

[0031] The humectant may comprise at least one of: propylene glycol, glycerol, water.

[0032] The flavorant may comprise at least one of: menthol, L-carvone, ethyl methylphenylglycidate, peppermint oil.

[0033] The botanical component may comprise at least one of: tobacco, clove, tea.

[0034] The pharmacologically-active agent may comprise at least one of: nicotine, cannabidiol, tetrahydrocannabinol.

[0035] The gelling agent may comprise at least one of: sodium alginate, guar gum.

[0036] At least one of the stacked layers may comprise at least one of: paper, cellulose, cotton, non-woven fibres, botanical fibres. At least one of the stacked layers, and preferable all of the stacked layers, may be made of a material that is biodegradable or easily recyclable. This can help to reduce environmental impact after a consumable article has been used. The material of the at least one of the stacked layers may be substantially porous or absorbent, which may help to retain the sensorial medium prior to heating and vaporization.

[0037] The second, corrugated layer may be joined to the first, substantially flat layer by an adhesive.

[0038] The second, corrugated layer may be joined to the third, substantially flat layer by an adhesive.

[0039] The adhesive may be applied to ridge peaks of the second, corrugated layer before contacting the second, corrugated layer with the first, substantially flat layer and, where used, the third, substantially flat layer.

[0040] The consumable article may have a width substantially orthogonal to a corrugation direction of the second, corrugated layer of 10 to 40 millimetres, preferably 15 to 30 millimetres, more preferably 18 to 24 millimetres.

[0041] The consumable article may have a length substantially parallel to a corrugation direction of the second, corrugated layer of 20 to 50 millimetres, preferably 20 to 40 millimetres, more preferably 23 to 35 millimetres.

[0042] The consumable article may have a thickness of 1.2 to 30 millimetres, preferably 3 to 20 millimetres, more preferably 4.6 to 12.4 millimetres.

[0043] The first, substantially flat layer and, where present, the second, substantially flat layer may each have a thickness of 0.1 to 5 millimetres, preferably 0.5 to 2.5 millimetres, more preferably 0.8 to 1.2 millimetres.

[0044] The second, corrugated layer may have a peak-to-trough thickness of 1 to 10 millimetres, preferably 1 to 7.5 millimetres, more preferably 1 to 5 millimetres.

[0045] The second, corrugated layer may have a peak-to-peak pitch of 3 to 12 millimetres, preferably 3 to 10 millimetres, more preferably 3 to 8 millimetres.

[0046] The second, corrugated layer may have a surface-to-surface thickness of 0.1 to 5 millimetres, preferably 0.5 to 2.5 millimetres, more preferably 0.8 to 1.2 millimetres.

[0047] According to a second aspect of the present invention, there is provided a method of making a substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the method comprising the steps of:

[0048] i) providing a first substrate to form a first, substantially flat layer;

[0049] ii) providing a second substrate and forming corrugations in the second substrate for form a second, corrugated layer; and

[0050] iii) joining the first and second layers to each other with an adhesive to form a stacked layer structure;

[0051] wherein the method further comprises applying a sensorial medium to the first substrate or to the second substrate or to both the first substrate and the second substrate. The method may further comprise:

[0052] iv) providing a third substrate to form a third, substantially flat layer;

[0053] v) joining the second and third layers to each other with an adhesive.

[0054] The respective substrates may unwound from respective bobbins. Each bobbin may hold a relatively long length of substrate, for example tens of metres, hundreds of metres or thousands of metres, thus providing sufficient substrate material for the method to be performed continuously for a period of time without the need to stop the method in order to provide more substrate.

[0055] The method may further comprise applying the sensorial medium to the third substrate. The second substrate may be passed between a pair of corrugated rollers so as to form the corrugations in the second substrate.

[0056] The sensorial medium may be a liquid or gel.

[0057] The sensorial medium may be sprayed or coated onto the respective substrate. For example, the sensorial medium may be sprayed by way of one or more nozzles. For example, the sensorial medium may be coated onto the substrate by way of a sponge or brush, or the substrate may be dipped in or pass through a bath of sensorial medium.

[0058] The sensorial medium may be applied to corrugations of the second substrate after the corrugations have been formed in the second substrate.

[0059] The sensorial medium may be injected between the first and second substrates after the first and second substrates have been joined together.

[0060] The sensorial medium may be injected between the second and third substrates after the second and third substrates have been joined together.

[0061] The stacked layer structure may be cut into individual consumable articles. The individual consumable articles may be as described in the first aspect of the present invention.

[0062] At least one of the substrates may be made of a material that inherently releases an aerosol when heated. The material may comprise at least one of: tobacco cast leaf, reconstituted tobacco, tobacco leaf, homogenized tobacco or other forms of tobacco, optionally blended with paper or cellulose fibres. The material may comprise a blend of paper or cellulose fibres and a nicotine-containing composition other than tobacco.

[0063] The sensorial medium may comprise nicotine. The nicotine may be pharmaceutical-grade or synthetic nicotine. The sensorial medium may comprise tobacco or tobacco extracts. The tobacco or tobacco extracts may be obtained from natural tobacco. In some embodiments, the sensorial medium does not comprise tobacco or tobacco extracts.

[0064] The first substrate may comprise a metallic susceptor layer. The second substrate may comprise a metallic susceptor layer. The method may include a step of applying the metallic susceptor layer to the respective substrate. For example, the metallic susceptor layer may comprise a metallic foil, and may be adhered to the respective substrate. The sensorial medium may comprise at least one of: humectant, flavorant, botanical component, pharmacologically-active agent, gelling agent. The humectant may comprise at least one of: propylene glycol, glycerol, water. The flavorant may comprise at least one of: menthol, L-carvone, ethyl methylphenylglycidate, peppermint oil. The botanical component may comprise at least one of: tobacco, clove, tea. The pharmacologically-active agent may comprise at least one of: nicotine, cannabidiol, tetrahydrocannabinol. The gelling agent may comprise at least one of: sodium alginate, guar gum.

[0065] According to a third aspect of the present invention, there is provided a method of making a substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the method comprising the steps of:

[0066] i) providing a first substrate to form a first, substantially flat layer;

[0067] ii) providing a second substrate and forming corrugations in the second substrate for form a second, corrugated layer having substantially parallel peaks and troughs; and

[0068] iii) joining the first and second layers to each other with an adhesive to form a stacked layer structure;

[0069] wherein the method further comprises applying a sensorial medium to the second substrate so as at least partially to fill the troughs of the second, corrugated layer with the sensorial medium.

[0070] The method may further comprise:

[0071] iv) providing a third substrate to form a third, substantially flat layer;

[0072] v) joining the second and third layers to each other with an adhesive.

[0073] The second substrate may be passed between a pair of corrugated rollers so as to form the corrugations in the second substrate.

[0074] The sensorial medium may be sprayed or coated onto the second substrate.

[0075] The sensorial medium may be applied to corrugations of the second substrate after the corrugations have been formed in the second substrate.

[0076] The sensorial medium may be sprayed or coated onto an exposed surface of the second substrate before the second and third layers are joined to each other.

[0077] The sensorial medium may be injected between the first and second substrates after the first and second substrates have been joined together.

[0078] The sensorial medium may be injected between the second and third substrates after the second and third substrates have been joined together.

[0079] The sensorial medium may be applied to the second substrate in the form of a liquid, gel or slurry.

[0080] The stacked layer structure may be cut into individual consumable articles.

[0081] At least one of the substrates may be made of a material that inherently releases an aerosol when heated. The sensorial medium may comprise tobacco or tobacco extracts.

[0082] Alternatively, the sensorial medium does not comprise tobacco or tobacco extracts.

[0083] At least one of the substrates may comprise a metallic susceptor layer.

[0084] The sensorial medium may comprise at least one of: a humectant, a flavorant, a botanical component, a pharmacologically-active agent, a gelling agent.

[0085] As used herein, the term “aerosol-generating consumable article” is intended to mean an article configured to be used with an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol.

[0086] As used herein, the term “aerosol-generating device” refers to a device configured to generate an aerosol from an aerosol-generating consumable article. The aerosol-generating consumable article comprises a sensorial medium that, when heated, releases an aerosol. An aerosol-generating device comprises a power source, control circuitry and a heating mechanism to heat the aerosol-generating consumable article.

[0087] As used herein, the term “corrugated” refers to a sheet of material in which substantially parallel peaks and troughs, or ridges and grooves, have been formed, for example to impart additional rigidity and strength.

[0088] As used herein, the term “metallic susceptor” refers to a substantially laminar metal element, for example in the form of a metal foil, that is disposed on or adjacent to a substrate, and which can be heated by resistive or inductive heating.

[0089] As used herein, the term “sensorial medium” is intended to mean a medium that releases an aerosol when heated. A sensorial medium may be applied to a substrate as a liquid, gel or slurry. Alternatively, a substrate may be made of or may be impregnated with a sensorial medium.

[0090] As used herein, the term “stacked layers” is intended to mean two or more layers that are formed one on top of the other so as to form a multilayer stack.

[0091] As used herein, the term “substantially planar” is intended to refer to an article that is substantially flat or laminar, having a length and a width substantially greater than a thickness of the article.

[0092] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0093] Example Ex1: A substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the consumable article comprising a plurality of stacked layers, the plurality of stacked layers comprising at least a first, substantially flat layer and a second, corrugated layer, the first and second layers being joined to each other, and wherein at least one of the stacked layers is made of or is provided with a sensorial medium that releases an aerosol when heated. Example Ex2: The consumable article according to Example Ex1 , further comprising a third, substantially flat layer, wherein the second, corrugated layer is sandwiched between the first and third layers.

[0094] Example Ex3: The consumable article according to Example Ex1 or Ex2, wherein at least one of the stacked layers is made of a material that inherently releases an aerosol when heated.

[0095] Example Ex4: The consumable article according to Example Ex3, wherein the material comprises tobacco cast leaf, reconstituted tobacco, tobacco leaf, homogenized tobacco or other forms of tobacco, optionally blended with paper or cellulose fibres.

[0096] Example Ex5: The consumable article according to Example Ex3, wherein the material comprises a blend of paper or cellulose fibres and a nicotine-containing composition other than tobacco.

[0097] Example Ex6: The consumable article according to any preceding Example, wherein the at least one of the stacked layers is impregnated with the sensorial medium.

[0098] Example Ex7: The consumable article according to any preceding Example, wherein the at least one of the stacked layers is coated with the sensorial medium.

[0099] Example Ex8: The consumable article according to Example Ex6 or Ex7, wherein the sensorial medium is a liquid.

[0100] Example Ex9: The consumable article according to Example Ex6 or Ex7, wherein the sensorial medium is a gel.

[0101] Example Ex10: The consumable article according to Example Ex6 or Ex7, wherein the sensorial medium is a slurry.

[0102] Example Ex11: The consumable article according to any one of Examples Ex6 to Ex10, wherein the sensorial medium comprises nicotine.

[0103] Example Ex12: The consumable article according to any one of Examples Ex6 to Ex11, wherein the sensorial medium comprises tobacco or tobacco extracts.

[0104] Example Ex13: The consumable article according to any one of Examples Ex6 to Ex11, wherein the sensorial medium does not comprise tobacco or tobacco extracts.

[0105] Example Ex14: The consumable article according to any preceding Example, wherein each layer is made of or is provided with the sensorial medium.

[0106] Example Ex15: The consumable article according to any one of Examples Ex1 to Ex13, wherein not all of the layers are made of or are provided with the sensorial medium.

[0107] Example Ex16: The consumable article according to any one of Examples Ex1 to Ex13, wherein only the first, substantially flat layer is made of or is provided with the sensorial medium.

[0108] Example Ex17: The consumable article according to any one of Examples Ex1 to Ex13, wherein only the second, corrugated layer is made of or is provided with the sensorial medium. Example Ex18: The consumable article according to Example Ex2 or any one of Examples Ex3 to Ex13 depending from Example Ex2, wherein only the third, substantially flat layer is made of or is provided with the sensorial medium.

[0109] Example Ex19: The consumable article according to any preceding Example, comprising a metallic susceptor.

[0110] Example Ex20: The consumable article according to Example Ex19, wherein the first, substantially flat layer is or comprises the metallic susceptor.

[0111] Example Ex21: The consumable article according to Example Ex19 or Ex20 depending from Example Ex2 or any one of Examples Ex3 to Ex18 depending from Example Ex2, wherein the third, substantially flat layer is or comprises the metallic susceptor.

[0112] Example Ex22: The consumable article according to Example Ex20 or Ex21, wherein the metallic susceptor comprises a metal layer formed on the respective substantially flat layer.

[0113] Example Ex23: The consumable article according to Example Ex22, wherein the metal layer is formed on a surface of the respective substantially flat layer opposite to a surface joined to the second, corrugated layer.

[0114] Example Ex24: The consumable article according to any one of Examples Ex19 to Ex23, wherein the metallic susceptor comprises or consists of aluminium, aluminium alloy, 8011 aluminium alloy, stainless steel, 304 stainless steel, stainless steel with a nickel coating, or 304 stainless steel with a nickel coating.

[0115] Example Ex25: The consumable article according to any one of Examples Ex19 to Ex24, wherein the metallic susceptor has a thickness of 10 micrometres to 30 micrometres.

[0116] Example Ex26: The consumable article according to any preceding Example, wherein the second, corrugated layer defines a plurality of substantially parallel airflow channels configured to allow a flow of air from one edge of the consumable article to an opposed edge of the consumable article in a plane of the consumable article when the consumable article is inserted into the aerosol-generating device.

[0117] Example Ex27: The consumable article according to Example Ex26, wherein the airflow channels are configured to provide a resistance to draw from the one edge to the opposed edge of the consumable articles of 0 to 80 millimetres Water Gauge, preferably 0 to 20 millimetres Water Gauge, more preferably 0 to 10 millimetres Water Gauge.

[0118] Example Ex28: The consumable article according to any preceding Example, wherein the sensorial medium is disposed in corrugations of the second, corrugated layer.

[0119] Example Ex29: The consumable article according to any preceding Example, wherein the sensorial medium comprises at least one of: humectant, flavorant, botanical component, pharmacologically-active agent, gelling agent.

[0120] Example Ex30: The consumable article according to Example Ex29, wherein the humectant comprises at least one of: propylene glycol, glycerol, water. Example Ex31: The consumable article according to Example Ex29 or Ex30, wherein the flavorant comprises at least one of: menthol, L-carvone, ethyl methylphenylglycidate, peppermint oil.

[0121] Example Ex32: The consumable article according to any one of Examples Ex29 to Ex31, wherein the botanical component comprises at least one of: tobacco, clove, tea.

[0122] Example Ex33: The consumable article according to any one of Examples Ex29 to Ex32, wherein the pharmacologically-active agent comprises at least one of: nicotine, cannabidiol, tetrahydrocannabinol.

[0123] Example Ex34: The consumable article according to any one of Examples Ex29 to Ex33, wherein the gelling agent comprises at least one of: sodium alginate, guar gum.

[0124] Example Ex35: The consumable article according to any preceding Example, wherein at least one of the stacked layers comprises at least one of: paper, cellulose, cotton, non-woven fibres, botanical fibres.

[0125] Example Ex36: The consumable article according to any preceding Example, wherein the second, corrugated layer is joined to the first, substantially flat layer by an adhesive.

[0126] Example Ex37: The consumable article according to Example Ex2 or any one of Examples Ex3 to Ex36 depending from Example Ex2, wherein the second, corrugated layer is joined to the third, substantially flat layer by an adhesive.

[0127] Example Ex38: The consumable article according to any preceding Example, having a width substantially orthogonal to a corrugation direction of the second, corrugated layer of 10 to 40 millimetres, preferably 15 to 30 millimetres, more preferably 18 to 24 millimetres.

[0128] Example Ex39: The consumable article according to any preceding Example, having a length substantially parallel to a corrugation direction of the second, corrugated layer of 20 to 50 millimetres, preferably 20 to 40 millimetres, more preferably 23 to 35 millimetres.

[0129] Example Ex40: The consumable article according to any preceding Example, having a thickness of 1.2 to 30 millimetres, preferably 3 to 20 millimetres, more preferably 4.6 to 12.4 millimetres.

[0130] Example Ex41: The consumable article according to any preceding Example, wherein the first, substantially flat layer and, where present, the second, substantially flat layer each have a thickness of 0.1 to 5 millimetres, preferably 0.5 to 2.5 millimetres, more preferably 0.8 to 1.2 millimetres.

[0131] Example Ex42: The consumable article according to any preceding Example, wherein the second, corrugated layer has a peak-to-trough thickness of 1 to 10 millimetres, preferably 1 to 7.5 millimetres, more preferably 1 to 5 millimetres.

[0132] Example Ex43: The consumable article according to any preceding Example, wherein the second, corrugated layer has a peak-to-peak pitch of 3 to 12 millimetres, preferably 3 to 10 millimetres, more preferably 3 to 8 millimetres. Example Ex44: The consumable article according to any preceding Example, wherein the second, corrugated layer has surface-to-surface thickness of 0.1 to 5 millimetres, preferably 0.5 to 2.5 millimetres, more preferably 0.8 to 1.2 millimetres.

[0133] Example Ex45: A method of making a substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the method comprising the steps of:

[0134] i) providing a first substrate to form a first, substantially flat layer;

[0135] ii) providing a second substrate and forming corrugations in the second substrate for form a second, corrugated layer; and

[0136] iii) joining the first and second layers to each other with an adhesive to form a stacked layer structure;

[0137] wherein the method further comprises applying a sensorial medium to the first substrate or to the second substrate or to both the first substrate and the second substrate.

[0138] Example Ex46: The method according to Example Ex45, further comprising:

[0139] iv) providing a third substrate to form a third, substantially flat layer;

[0140] v) joining the second and third layers to each other with an adhesive.

[0141] Example Ex47: The method according to Example Ex46, further comprising applying the sensorial medium to the third substrate.

[0142] Example Ex48: The method according to any one of Examples Ex45 to Ex47, wherein the second substrate is passed between a pair of corrugated rollers so as to form the corrugations in the second substrate.

[0143] Example Ex49: The method according to any one of Examples Ex45 to Ex48, wherein the sensorial medium is a liquid or gel.

[0144] Example Ex50: The method according to any one of Examples Ex45 to Ex49, wherein the sensorial medium is sprayed or coated onto the respective substrate.

[0145] Example Ex51: The method according to any one of Examples Ex45 to Ex50, wherein the sensorial medium is applied to corrugations of the second substrate after the corrugations have been formed in the second substrate.

[0146] Example Ex52: The method according to any one of Examples Ex45 to Ex51, wherein the sensorial medium is injected between the first and second substrates after the first and second substrates have been joined together.

[0147] Example Ex53: The method according to Example Ex46 or any one of Examples Ex47 to Ex52 depending from Example Ex46, wherein the sensorial medium is injected between the second and third substrates after the second and third substrates have been joined together.

[0148] Example Ex54: The method according to any one of Examples Ex45 to Ex53, wherein the stacked layer structure is cut into individual consumable articles. Example Ex55: The method according to any one of Examples Ex45 to Ex53, wherein at least one of the substrates is made of a material that inherently releases an aerosol when heated.

[0149] Example Ex56: The method according to Example Ex55, wherein the material comprises tobacco cast leaf, reconstituted tobacco, tobacco leaf, homogenized tobacco or other forms of tobacco, optionally blended with paper or cellulose fibres.

[0150] Example Ex57: The method according to Example Ex55, wherein the material comprises a blend of paper or cellulose fibres and a nicotine-containing composition other than tobacco.

[0151] Example Ex58: The method according to any one of Examples Ex45 to Ex57, wherein the sensorial medium comprises nicotine.

[0152] Example Ex59: The method according to any one of Examples Ex45 to Ex58, wherein the sensorial medium comprises tobacco or tobacco extracts.

[0153] Example Ex60: The method according to any one of Examples Ex45 to Ex58, wherein the sensorial medium does not comprise tobacco or tobacco extracts.

[0154] Example Ex61: The method according to any one of Examples Ex45 to Ex60, wherein the first substrate comprises a metallic susceptor layer.

[0155] Example Ex62: The method according to Example Ex46 or any one of Examples Ex47 to Ex61, wherein the second substrate comprises a metallic susceptor layer.

[0156] Example Ex63: The method according to any one of Examples Ex45 to Ex62, wherein the sensorial medium comprises at least one of: humectant, flavorant, botanical component, pharmacologically-active agent, gelling agent.

[0157] Example Ex64: The method according to Example Ex63, wherein the humectant comprises at least one of: propylene glycol, glycerol, water.

[0158] Example Ex65: The method according to Example Ex63 or Ex64, wherein the flavorant comprises at least one of: menthol, L-carvone, ethyl methylphenylglycidate, peppermint oil.

[0159] Example Ex66: The method according to any one of Examples Ex63 to Ex65, wherein the botanical component comprises at least one of: tobacco, clove, tea.

[0160] Example Ex67: The method according to any one of Examples Ex63 to Ex66, wherein the pharmacologically-active agent comprises at least one of: nicotine, cannabidiol, tetrahydrocannabinol.

[0161] Example Ex68: The method according to any one of Examples Ex63 to Ex67, wherein the gelling agent comprises at least one of: sodium alginate, guar gum.

[0162] Example Ex69: A method of making a substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the method comprising the steps of:

[0163] i) providing a first substrate to form a first, substantially flat layer;

[0164] ii) providing a second substrate and forming corrugations in the second substrate for form a second, corrugated layer having substantially parallel peaks and troughs; and iii) joining the first and second layers to each other with an adhesive to form a stacked layer structure;

[0165] wherein the method further comprises applying a sensorial medium to the second substrate so as at least partially to fill the troughs of the second, corrugated layer with the sensorial medium.

[0166] Example Ex70: The method according to Example Ex69, further comprising:

[0167] iv) providing a third substrate to form a third, substantially flat layer;

[0168] v) joining the second and third layers to each other with an adhesive.

[0169] Example Ex71: The method according to Example Ex69 or Ex70, wherein the second substrate is passed between a pair of corrugated rollers so as to form the corrugations in the second substrate.

[0170] Example Ex72: The method according to any one of Examples Ex69 to Ex71, wherein the sensorial medium is sprayed or coated onto the second substrate.

[0171] Example Ex73: The method according to Example Ex72, wherein the sensorial medium is applied to corrugations of the second substrate after the corrugations have been formed in the second substrate.

[0172] Example Ex74: The method according to Example Ex72 or Ex73 depending from Example Ex70, wherein the sensorial medium is sprayed or coated onto an exposed surface of the second substrate before the second and third layers are joined to each other.

[0173] Example Ex75: The method according to any one of Examples Ex69 to Ex 74, wherein the sensorial medium is injected between the first and second substrates after the first and second substrates have been joined together.

[0174] Example Ex76: The method according to Example Ex70 or any one of Examples Ex71 to Ex75 depending from Example Ex70, wherein the sensorial medium is injected between the second and third substrates after the second and third substrates have been joined together.

[0175] Example Ex77: The method according to any one of Examples Ex69 to Ex76, wherein the sensorial medium is applied to the second substrate in the form of a liquid, gel or slurry.

[0176] Example Ex78: The method according to any one of Examples Ex69 to Ex77, wherein the stacked layer structure is cut into individual consumable articles.

[0177] Example Ex79: The method according to any one of Examples Ex69 to Ex78, wherein at least one of the substrates is made of a material that inherently releases an aerosol when heated.

[0178] Example Ex80: The method according to any one of Examples Ex69 to Ex79, wherein the sensorial medium comprises tobacco or tobacco extracts.

[0179] Example Ex81: The method according to any one of Examples Ex69 to Ex79, wherein the sensorial medium does not comprise tobacco or tobacco extracts.

[0180] Example Ex82: The method according to any one of Examples Ex69 to Ex81, wherein at least one of the substrates comprises a metallic susceptor layer. Example Ex83: The method according to any one of Examples Ex69 to Ex82, wherein the sensorial medium comprises at least one of: a humectant, a flavorant, a botanical component, a pharmacologically-active agent, a gelling agent.

[0181] Examples will now be further described with reference to the figures in which:

[0182] Figure 1 shows an aerosol-generating consumable article in perspective view;

[0183] Figure 2 shows the aerosol-generating consumable article of Figure 1 in cross-sectional view;

[0184] Figure 3 shows the aerosol-generating consumable article of Figure 1 with various dimensions labelled for reference;

[0185] Figure 4 shows the aerosol-generating consumable article of Figure 2 with various dimensions labelled for reference;

[0186] Figure 5 shows, in schematic form, a process for manufacturing the aerosol-generating consumable article of Figures 1 to 4;

[0187] Figure 6 shows, in cross-sectional view, a partially-assembled strip of aerosol-generating consumable articles before application of liquid, gel or slurry sensorial medium; and

[0188] Figure 7 shows, in cross-sectional view, a partially-assembled strip of aerosol-generating consumable articles after application of liquid, gel or slurry sensorial medium.

[0189] Figures 1 and 2 show, in schematic form, an exemplary aerosol-generating consumable article 100 of an embodiment of the present invention. The consumable article 100, which has a substantially planar form factor (the vertical dimensions are exaggerated in the drawings to show the structure more clearly), comprises a plurality of stacked layers. In the illustrated embodiment, the consumable article 100 comprises a first, substantially flat layer 110; a second, corrugated layer 120; and a third, substantially flat layer 130. The layers 110, 120 and 130 are stacked on top of each other, with the second, corrugated layer 120 between the first and second substantially flat layers 110, 130. The structure of the consumable article 100 is similar to the structure of corrugated cardboard. The particular embodiment shown in Figures 1 and 2 has a single wall structure (i.e. a single corrugated layer between two flat layers), but other embodiments may have a single face structure (i.e. a single flat layer and a single corrugated layer), a double wall structure (i.e. a first flat layer, a second corrugated layer, a third flat layer, a fourth corrugated layer, a fifth flat layer) or an N-tuple wall structure (i.e. top and bottom flat layers with N corrugated layers therebetween, the corrugated layers being separated by respective flat layers).

[0190] In Figures 1 and 2, the second, corrugated layer 120 comprises longitudinal flutes with troughs 160 and peaks 170. The longitudinal flutes form longitudinal channels 180 defining air flow paths from one edge to an opposed edge of the consumable article 100.

[0191] The peaks 170 of the second, corrugated layer 120 are joined to an underside of the first, substantially flat layer 110 by an adhesive 190. Undersides of the troughs 160 of the second, corrugated layer 120 are joined to a topside of the second, substantially flat layer 130, also by an adhesive 190.

[0192] The outer exposed surface of one or other or both of the first and second, substantially flat layers 110, 130 may be provided with a backing layer 115. The backing layer 115 may be a metallic susceptor layer, for example a metallic foil. As previously discussed, a metallic susceptor layer 115 may serve to distribute heat evenly across the outer exposed surface of the respective flat layer 110, 130, and in some cases may itself serve as a heat source by using electromagnetic induction to generate eddy currents in the metallic susceptor layer 115. Alternatively or in addition, the backing layer 115 may be a barrier layer that is substantially impermeable to air or to water or to both air and water. Alternatively or in addition, the backing layer 115 may be a paper-based layer, for example cigarette paper or tipping paper.

[0193] At least one of the layers 110, 120, 130 is made of or is provided with a sensorial medium that releases an aerosol when heated.

[0194] In the embodiment of Figures 1 and 2, a sensorial medium in the form of a liquid, gel or slurry 140, 150 is provided in the peaks 170 and troughs 160 of the second, corrugated layer 120. Preferably, the sensorial medium liquid, gel or slurry 140, 150 is provided along substantially the entire lengths of the longitudinal channels 180. The peaks 170 and troughs 160 thus serve as reservoirs for the sensorial medium liquid, gel or slurry 140, 150.

[0195] In addition to, or as an alternative to, providing sensorial medium liquid, gel or slurry 140, 150, it is possible that at least one of the layers 110, 120, 130 is made of a material that inherently releases an aerosol when heated. For example, at least one of the layers may be made of tobacco cast leaf, reconstituted tobacco, tobacco leaf, homogenized tobacco or other forms of tobacco, optionally blended with paper or cellulose fibres.

[0196] It is also possible for at least one of the layers 110, 120, 130 to be made of a blend of paper or cellulose fibres and a nicotine composition other than tobacco, configured to release a nicotine-containing aerosol when heated.

[0197] At least one of the layers 110, 120, 130 may be impregnated with a sensorial medium prior to or during manufacture of the consumable article 100, or may be coated with a sensorial medium prior to or during manufacture of the consumable article 100.

[0198] The first and second, substantially flat layers 110, 130 may be the same or different.

[0199] With reference now to Figures 3 and 4, these show the consumable article 100 of Figures 1 and 2 but labelled to show the dimensions of the components of the consumable article 100.

[0200] Specifically, Figures 3 and 4 show a width W and a length L of the consumable article 100. The consumable article 100 also has a total thickness Tp. The first layer 110 has a thickness Ta, and the third layer 130 has a thickness Tb. The second, corrugated layer 120 has a peak-to-trough thickness Tf, and a wall thickness Tm. The second, corrugated layer 120 also has a pitch A, being the peak-to-peak or trough-to-trough distance. As seen best in Figure 3, sensorial medium liquid, gel or slurry 140 may be filled to a depth of Ti in the troughs 160 of the second, corrugated layer. Sensorial medium liquid, gel or slurry 150 may also be similarly filled in the undersides of the peaks 170 of the second, corrugated layer. The sensorial medium liquid, gel or slurry 140, 150 may remain in place, regardless of the orientation of the consumable article 100, due to capillary forces.

[0201] The backing layer 115, where present, may have a thickness Tg.

[0202] Figure 3 shows a direction of airflow through the longitudinal channels 180. The consumable article 100 is configured for use with an aerosol-generating device (not shown) that comprises a power supply, control electronics and a mechanism for heating the consumable article 100 so that the consumable article 100 releases an aerosol. The aerosol-generating device comprises a mouthpiece through which a consumer is able to suck or inhale. The mouthpiece is in fluid communication with the longitudinal channels 180 at one edge of the consumable article 100, and the longitudinal channels 180 at the opposed edge of the consumable article 100 are in fluid communication with external atmosphere. Accordingly, when a consumer sucks or inhales at the mouthpiece, air is drawn from the external atmosphere, along the longitudinal channels 180, and into the consumer’s mouth. When the consumable article 100 is heated by the aerosolgenerating device, aerosol is released by the sensorial medium and entrained in the airflow through the longitudinal channels 180. The action of sucking or inhaling at the mouthpiece allows the consumer to enjoy the aerosol entrained in the airflow.

[0203] The longitudinal channels 180 may be configured to establish a desired resistance to draw for the airflow. Embodiments of the present invention allow a very low resistance to draw to be achieved, for example from 0 to 80 millimetres Water Gauge, preferably 0 to 20 millimetres Water Gauge, more preferably 0 to 10 millimetres Water Gauge, and in some cases substantially 0 millimetres Water Gauge.

[0204] As illustrated in Figure 4, the construction of the consumable article 100 with a corrugated layer 120 between first and second substantially flat layers 110, 130 results in a structure that is resistance to compression in the Z direction, as well as being resistant to bending. The wall thickness Tm and the pitch A, as well as the peak-to-trough thickness Tf, are the main factors that determine the compressive strength of the consumable article 100. Generally, a greater wall thickness Tm (of a given material) will result in greater compressive strength. A shorter pitch A and a higher number of peaks or troughs per unit width W will generally also increase compressive strength. In some instances, it may be desirable that the consumable article 100 can be compressed slightly upon insertion into an aerosol-generating device so as to improve interaction with heating mechanisms in the aerosol-generating device, in which case the pitch A can be increased, or the peak-to-trough thickness Tf, or both.

[0205] The consumable article 100 may be configured such that a compressive force in the Z direction, applied by a load having a contact area equal to the surface area of the largest face of the consumable article, required to compress the consumable article by 1 millimetre is from 1 to 50 newtons, preferably from 5 to 30 newtons, most preferably from 7.5 to 20 newtons.

[0206] The second, corrugated layer 120 can also act as a stable support structure for the first and third, substantially flat layers 110, 130, and help to reduce possible shrinkage due to loss of moisture as the sensorial medium is consumed. This can help to maintain stable and consistent thermal transfer by ensuring good contact with heating elements, for example planar heating elements, in the aerosol-generating device.

[0207] Although not intended to be necessarily limiting, exemplary dimensions may be as set out in the table below:

[0208] Range Preferable Most Preferable Ta 0.1 to 5mm 0.5 to 2.5mm 0.8 to 1.2mm

[0209] Tb 0.1 to 5mm 0.5 to 2.5mm 0.8 to 1.2mm

[0210] Tf 1 to 10mm 1 to 7.5mm 1 to 5mm

[0211] Tp 1.2 to 30mm 3 to 20mm 4.6 to 12.4mm

[0212] Tm 0.1 to 5mm 0.5 to 2.5mm 0.8 to 1.2mm

[0213] Tg 0.01 to 0.2mm 0.05 to 0.15mm 0.075 to 0.1mm Ti 1 to 100% of Tf 25 to 75% of Tf 40 to 60% of Tf A 3 to 12mm 3 to 10mm 3 to 8mm

[0214] W 10 to 40mm 15 to 30mm 18 to 24mm

[0215] L 20 to 50mm 20 to 40mm 23 to 35mm

[0216]

[0217] With reference to Figure 5, there is shown, in schematic form, a process for manufacturing the consumable article 100.

[0218] A roll of material, referred to here as a first board layer, that will form the first, substantially flat layer 110 is loaded by way of a first bobbin 311 and fed through and kept under tension by way of a tension roller 312. Simultaneously, a roll of material that will form the second, corrugated layer 120 is loaded by way of a second bobbin 316 and kept under tension by way of tension roller 317. The material from the second bobbin 316 passes between corrugating rollers 318, 319 so as to form corrugations in the material and thus form a fluted layer. An adhesive 315 is applied to peaks of the corrugations on one side of the fluted by way of an adhesive applicator roller 314. Thereafter the first board layer and the fluted layer are brought together at nip point of between a pressure roller 313 and corrugating roller 319, such that the adhesive 315 bonds the peaks of the corrugations in the fluted layer to the first board layer so to form a single face corrugated structure 200 as shown in Figure 6, where the first board layer is indicated at 110, the fluted layer is indicated at 120, and the adhesive is indicated at 190. A sensorial medium in the form of a liquid, gel or slurry 140 is applied to one side of the fluted layer of the single faced corrugated structure 200 by way of a sensorial medium applicator 333 so as at least partially to fill the exposed corrugations of the single faced corrugated structure with sensorial medium 140, as shown in Figure 7.

[0219] An adhesive 324 is then applied to the exposed peaks of the corrugations of the fluted layer by way of an adhesive applicator roller 325. A guide roller 323 acts to maintain the position of the single faced board structure during sensorial medium 140 application and subsequent application of adhesive 324.

[0220] A roll of material, referred to here as a second board layer, that will form the third, substantially flat layer 130 is loaded by way of a third bobbin 326 and fed through and kept under tension by way of a tension roller 327. Thereafter, the second board layer and the single face corrugated structure 200 are brought together at a pressure roller 328, such that the adhesive 324 bonds the exposed peaks of the fluted layer of the single face corrugated structure 200 to the second board layer to form a single wall corrugated structure 100. Optionally, further sensorial medium in the form of a liquid, gel or slurry 150 can then be injected into the fluted layer channels by way of a sensorial medium injector 334, to form a continuous sheet of the planar consumable article 100 as shown in Figures 1 and 2.

[0221] The continuous sheet is then cut, using a knife or punch 331 , into the desired finished planar consumable articles 100.

[0222] Although not shown in Figure 5, one or other or both of the first and second board layers may be provided with a backing layer 115 by feeding the backing layer 115 from one or more bobbins, optionally over one or more tension rollers, and adhering or otherwise attaching the backing layer 115 to a respective exposed surface of one or other or both of the first and second board layers. This may be done after the first and second board layers have been adhered to the fluted layer. Alternatively, the backing layer 115 may be applied to the first or second or both board layers before the layers have all been adhered together. Alternatively, the backing layer 115 may be applied to the first or second or both board layers before the respective board layers are wound onto their respective bobbins 311, 326. The backing layer 115 may be a metallic foil, configured to act as a metallic susceptor. Alternatively, the backing layer 115 may be a non-metallic barrier layer. The backing layer 115 on one of the first and second board layers may be a metallic foil, and on the other of the first and second board layers may be a non-metallic barrier layer.

[0223] The bobbins 311, 316, 326, the tension rollers 312, 317, 327, the guide rollers 313, 323, 328 and the corrugating rollers 318, 319 may each have a length of 30 to 4250 millimetres, preferably 125 to 1750 millimetres, most preferably 250 to 700 millimetres.

[0224] In embodiments where the rollers have very short lengths, close to 30 millimetres, the dispensed product need only be cut in a direction perpendicular to the direction of travel by knife or punch 331 in order to obtain individual consumable articles 100. However, it may be preferable, for reasons of efficient manufacture, to use longer rollers and wider webs of material for the first and second board layers and the fluted layer. In these embodiments, the knife or punch 331 is preferably configured to cut the dispensed product both in a direction perpendicular to the direction of travel and in a direction parallel to the direction of travel in order to obtain individual consumable articles 100.

[0225] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 5% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS:

1. A method of making a substantially planar aerosol-generating consumable article configured for insertion into an aerosol-generating device comprising electronic circuitry to heat the consumable article so as to generate an aerosol, the method comprising the steps of:i) providing a first substrate to form a first, substantially flat layer;ii) providing a second substrate and forming corrugations in the second substrate for form a second, corrugated layer having substantially parallel peaks and troughs; andiii) joining the first and second layers to each other with an adhesive to form a stacked layer structure;wherein the method further comprises applying a sensorial medium to the second substrate so as at least partially to fill the troughs of the second, corrugated layer with the sensorial medium.

2. The method according to claim 1, further comprising:iv) providing a third substrate to form a third, substantially flat layer;v) joining the second and third layers to each other with an adhesive.

3. The method according to claim 1 or 2, wherein the second substrate is passed between a pair of corrugated rollers so as to form the corrugations in the second substrate.

4. The method according to any one of claims 1 to 3, wherein the sensorial medium is sprayed or coated onto the second substrate.

5. The method according to claim 4, wherein the sensorial medium is applied to corrugations of the second substrate after the corrugations have been formed in the second substrate.

6. The method according to claim 4 or 5 depending from claim 2, wherein the sensorial medium is sprayed or coated onto an exposed surface of the second substrate before the second and third layers are joined to each other.

7. The method according to any preceding claim, wherein the sensorial medium is injected between the first and second substrates after the first and second substrates have been joined together.

8. The method according to claim 2 or any one of claims 3 to 7 depending from claim 2, wherein the sensorial medium is injected between the second and third substrates after the second and third substrates have been joined together.

9. The method according to any preceding claim, wherein the sensorial medium is applied to the second substrate in the form of a liquid, gel or slurry.

10. The method according to any preceding claim, wherein the stacked layer structure is cut into individual consumable articles.

11. The method according to any preceding claim, wherein at least one of the substrates is made of a material that inherently releases an aerosol when heated.

12. The method according to any preceding claim, wherein the sensorial medium comprises tobacco or tobacco extracts.

13. The method according to any one of claims 1 to 11 , wherein the sensorial medium does not comprises tobacco or tobacco extracts.

14. The method according to any preceding claim, wherein at least one of the substrates comprises a metallic susceptor layer.

15. The method according to any preceding claim, wherein the sensorial medium comprises at least one of: a humectant, a flavorant, a botanical component, a pharmacologically-active agent, a gelling agent.

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